Tufting machine with positive positioning means for backing material

ABSTRACT

The positive positioning means of the tufting machine of the present invention prevents lateral movement of the backing material as it passes beneath successive rows of tufting needles so that the rows of tufts are accurately positioned, relative to each other and to the backing material. This machine is particularly adapted for forming narrow or fine gauge pile fabrics, such as upholstery fabrics, carpet and the like wherein the rows of tufts are closely spaced. The positive positioning means includes a pair of endless chains having upper reaches supported for movement transversely of and adjacent opposite ends of the rows of tufting needles. Gripping means is carried by the chain for engaging the side edge portions of the backing material and for positively maintaining the lateral position of the backing material as it is moved beneath the successive rows of tufting needles.

States Patent [191 Unite Jackson Feb. 11, I975 Primary ExaminerWerner H.Schroeder Attorney, Agent, or Firm-Parrott, Bell. Seltzer. Park & Gibson[57] ABSTRACT The positive positioning means of the tufting machine ofthe present invention prevents lateral movement of the backing materialas it passes beneath successive rows of tufting needles so that the rowsof tufts are accurately positioned, relative to each other and to thebacking material. This machine is particularly adapted for formingnarrow or fine gauge pile fabrics, such as upholstery fabrics, carpetand the like wherein the rows of tufts are closely spaced. The positivepositioning means includes a pair of endless chains having upper reachessupported for movement transversely of and adjacent opposite ends of therows of tufting needles. Gripping means is carried by the chain forengaging the side edge portions of the backing material and forpositively maintaining the lateral position of the backing material asit is moved beneath the successive rows of tufting needles.

8 Claims, 4 Drawing Figures PATENTEDFYEABT 1191s I SHEET-1M2 TUFTINGMACHINE WITH POSITIVE POSITIONING MEANS FOR BACKING MATERIAL 'Thisinvention relates generally to tufting machines for forming narrow orfine gauge pile fabrics and more particularly to a tufting machine forforming such fabrics which includes a plurality of successive rows oftufting needles and positive positioning means to prevent lateralshifting of the backing material as its passes beneath successive rowsof tufting needles.

The prior James T. Cobble, U.S. Pat. No. 3,585,948 issued June 22, 1971,discloses a tufting machine particularly adapted for forming narrowgauge pile carpeting and the like. This machine includes first andsecond spaced apart rows of tufting needles and tracking means disposedbetween the first and second rows of needles for guiding the backingmaterial from the first row of needles to the second row of needles sothat the rows 'of tufts formed by the first row of needles pass throughthe spaces between the needles of the second row of needles. Thetracking means illustrated in this patent comprises first and secondgrooved tracking rolls supported for rotation between the first andsecond rows of tufting needles so that the rows of tufts formed by thefirst row of needles will be guided in a substantially straight line asthe backing material is fed to the second row of needles. The trackingmeans also includes a grooved guide bar positioned beneath the backingmaterial for aiding in maintaining the straight line path of travel ofthe backing material as it moves from the first row of needles to thesecond row of needles.

While the tufting machine illustrated in the prior Cobble patentoperates satisfactorily in the formation of narrow gauge pile carpeting,the addition of the grooved guide rolls and grooved guide bar, with theassociated mechanism for imparting longitudinal movement thereto, tendsto complicate the tufting machine. Also, the guide rolls and guide barof the tufting machine of the prior Cobble patent prevent lateralmovement of the backing material only in the area between the first andsecond rows of tufting needles.

With the foregoing in mind, it is an object of the present invention toprovide a tufting machine with positive positioning means to preventlateral shifting of the backing material prior to and during the time itpasses beneath the successive rows of tufting needles to insure properpositioning of the rows of tufts relative to the backing material and toinsure proper positioning of the rows of tufts formed by one row ofneedles, relative to rows of tufts formed by a succeeding row ofneedles.

In accordance with the present invention, the positive positioning meansincludes a pair of endless chains having upper reaches supported formovement tranversely of and adjacent opposite ends of the rows oftufting needles. Gripping means is carried by the chains for engagingthe side edge portions of the backing material and for positivelymaintaining the lateral position of the backing material as it is movedtoward and beneath the successive rows of tufting needles by the chains.The gripping means is preferably formed by a series of plates carried byand extending inwardly from each of the chains with pins being carriedby the plates and pointing upwardly along the upper reaches of thechains so that the opposite side edge portions of the backing materialare penetrated by the pins and positively held in position as thebacking material is fed through the tufting machine.

Other objects and advantages of the invention will appear as thedescription proceeds, when taken in connection with the accompanyingdrawings, in which:

FIG. 1 is an isometric view of a fragmentary portion of the tuftingmachine illustrating the backing material being guided into the machine;

FIG. 2 is a somewhat schematic sectional plan view with parts brokenaway and illustrating the manner in which the first and second row oftufting needles penetrate the backing material as it is guided throughthe tufting machine by the positive positioning means, in accordancewith the present invention;

FIG. 3 is a fragmentary isometric view of one side of the guide trackand chain, with parts in section and being taken substantially along theline 3-3 in FIG. 2;

FIG. 4 is a vertical sectional view through the tufting machine andillustrating the positive positioning means for feeding the backingmaterial beneath the successive rows of tufting needles.

Many of the parts of the tufting machine of the present invention areidentical to corresponding parts of the tufting machine illustrated inthe prior Cobble U.S. Pat. No. 3,585,948 which is incorporated herewithby reference, and which may be referred to for any of the details notdescribed in the present application. As had been indicated, the tuftingmachine of the present invention is particularly adapted for formingnarrow or fine gauge pile fabrics, such as upholstery fabrics and,carpets and the like. These fabrics include an elongate backing materialand yarns penetrating the backing material and forming closely spacedrows of tufts extending longitudinally of the backing material. As hasbeen pointed out in the prior Cobble patent, it is necessary to utilizetwo or more successive rows of tufting needles in order to form thenarrow or fine gauge pile fabric because the physical limitationsimposed in the lateral spacing of the pile forming instrumentalitiescooperating with the needles severely limit the close spacing of thepile needles.

Generally, the tufting machine of the present invention includes a frameor housing, broadly indicated at 10, (FIG. 1) including a bridgingsupport frame 11. A main drive shaft 12 (FIG. 4) is suitably connectedto the drive mechanism of the tufting machine housed in the end of theframe 10 in any suitable manner, not shown, and extends across thebridging frame 11. The main drive shaft 12 is continuously driven by theconventional drivemeans and a pair of rocker shafts 13, 13' are alsosupported in the bridging frame 11. Eccentric needle drive cams 14 arespaced along the main drive shaft 12 and are pivotally connected toneedle rocker arms l5, 15 which are in turn connected to the rockershafts 13, 13. Drive links 16, 16' are connected at their upper ends tothe rocker arms l5, l5 and their lower ends are connected to the upperends of respective needle drive rods 20, 20' which are suitablysupported for vertical movement in the bridging frame 11. The lower endsof the drive rods 20, 20' are fixedly connected to first and secondneedle bars 21, 21 carrying respective first and second spaced apartrows of tufting needles mounted for reciprocation in a verticaldirection transverse to the path of travel of the backing material,indicated at M, as it moved beneath the nee dles, in a manner to bepresently described.

Each of the needles carried inthe firstand second needle bars 21, 21'iscontinuously fed with respective yarns Y and Y' and by conventionaltension and guide rolls 22, 22 which draw the yarns from a suitablesupply, not shown. The yarns are directed to the needles throughsuitable guide means, in the form of guide bars 23, 23'. Pile formingmeans is disposed beneath the path of the backing material M and isoperatively associated witheach row of needles for forming rows of tuftson the lower face of the backing material. The pile forming means may beof any suitable type and is illustrated as including loopers 24 andknives 25 associated with the needle bar 21 and loopers 26 associatedwith the needle bar 21.

As best shown in FIG. 4, looper and knife drive shafts 30, 30 aresupported for reciprocation in the lower portion of the frame of themachine. Looper pivot shafts 31, 31 are also supported in the frame,along with a knife pivot shaft 32. A suitable drive connection,notshown, is provided between the main drive shaft 12 and the shafts 30,30' for. imparting oscillation thereto in synchronization with the,rotation of the main drive shaft 12. Thus, the vertical movement of thefirst and second needle bars 21, 21 is synchronized with the movement ofthe loopers 24, 26 and the knives 25.

As schematically illustrated in FIG. 2, the first needle bar 21 moves ina vertical reciprocating manner to produce straight rows of the yarns Ywhile the second needle bar 21 is shifted, first in one lateraldirection and then in the opposite lateral direction to produce a zigzagrow of the yarns Y and the needles in the second bar 21 penetrate thebacking material between the spaces between the rows of stitches formedby the yarns Y. However, it is to be understood that both of the needlebars could form straight rows of tufts. Also, if desired, both needlebars 21, 21 may be shifted back and forth so that they each producezig-zag rows of yarn. Also, the loop forming instrumentalitiesillustrated in cooperation with the first needle bar 21 are illustratedas forming a cut pile tuft while the instrumentalities associated withthe needles carriedby the second needle bar 21 are illustrated asforming looped tufts, however, it is to be understood that cut tufts maybe produced at each needle bar or looped tufts may be produced at eachneedlebar.

The positive positioning feed means of the tufting machine of thepresent invention includes a pair of endless chains 40, 40' having upperreaches which are supported for movement transversely of and adjacentopposite ends of the first and second rows of tufting needles carried bythe needle bars 21, 21'. A first pair of sprockets 41, 41 are supportedon a shaft 42 which is suitably supported for rotation adjacent oppositeends in support brackets 43, 43' (FIG. 2). A drive pinion 44 issupported on one end of the shaft 42 (FIG. 1) and is drivingly engagedby a gear 45 which is supported on the output shaft of the drive gearbox 46. An input shaft 47 of the gear box 46 is drivingly connected to adrive shaft 48 which is, in turn, drivingly connected to the tuftingmachine drive means, not shown, positioned inside of the housing 10.

A picker roll 50 (FIG. 2) having pins extending outwardly therefrom issupported between the first pair of sprockets 41, 41 and engages thebacking material as it is guided thereon in a manner to be presentlydescribed. A second pair of sprockets 52 is suitably supported forrotation adjacent the exit end of the tufting 4 machine. and supportsthe other end of the upper reaches of the chains 40, 40'. Lower pairs ofsprockets 53, 54 support the lower reaches of the endless chains 40, 40'and are suitably supported for rotation on the lower frame of thetufting machine.

A front cross-frame 55 and a rear cross-frame 56 extend beneath theupper reaches of the chains 40, 40' (FIG. 4) and support the respectivefront and rear ends of chain guide tracks 60, 60'. The guide tracks 60,60 are preferably made up of grooved upper and lower plates (FIG. 3) forengaging the chains and maintaining the upper reaches thereof moving instraight line paths of travel as they pass the first and second rows oftufting needles, carried by the needle bars 21, 21

Gripping means is provided on the chains 40, 40 for engaging the sideedge portions of the backing material M and for positively maintainingthe lateral position of the backing material as it is moved beneath thefirstand second needle bars 21, 21' by the chains 40 and 40. Asillustrated in FIG. 3, thegripping means includes a series of plates61which are carried byand fixed to the inner links of thechains'40 and40 and extend inwardly therefrom. Pins 62 are carried by the plates 61and point upwardly along the upper reaches of the chain so that theypenetrate the side edge portions of the backing material M as .it isdirected upwardly by the picker roll 50. I

Guide means is provided in advance of the picker roll 50 for spreadingthe outer edge portions of the backing materialM in a lateral directionas it is guided onto the picker roll 50 to be engaged by the pinsthereon. This guide-means is illustrated in the 'form of guide rolls 63,63' supported for rotation on support brackets 64, 64' and having pinsextending outwardly therefrom. The guide rolls 63, 63' are supported inangular relationship to cause a lateral spreading of the side edges ofthe backing'materials as they pass thereover. Guide rods 65, 65 are alsosupported on the brackets 64, 64and aid in maintaining the backingmaterial in engagement with the pins on the guide rolls 63, 63' as theopposite side edge portions of the backing material are guidedthereover.

Thus, the positive positioning feed means for the backing material gripsthe opposite side edge portions of the backing material and positivelyguides it beneath the first and second needle bars 21, 21' so that therecan be no sideways or lateral'movement of the backing material as itapproaches the first needle bar 21 and as it moves from the needle bar21 to the second bar 21. Therefore, the row of tufts formed by theneedles of the second needle bar 21' will be accurately positioned inthe middle of the space between the row of tufts formed by the needlesof the first needle bar.

In order to provide lateral adjustment of the path of movement of thebacking material beneath the needle bars and to also provide adjustmentof the lateral spacing between the conveying chains 40, 40' adjustmentmeans is operatively associated with at least one of the guide tracks60, 60' for adjusting the position of one guide track relative to theother guide track. As illustrated in FIGS. 2 and 3, this adjustmentmeans is associated with both guide tracks 60, 60 and comprisesadjustment links 70, the inner ends of which are fixedly secured to theouter extremities of the respective guide tracks 60, 60' and the outerends of which are suitably fixed to the upper surface of the frontcross-frame 55. The-guide tracks 60, 60 are maintained in adjustedposition by screws 71, 71' which are threadably imbedded in thecross-frame 55 and penetrate elongated slots in outwardly extendingbrackets 72, 72'.

in the drawings and specification there has been set forth preferredembodiment of the invention, and although specific terms are employed,they are used in a generic and descriptive sense only and not forpurposes of limitation, the scope of the invention being defined in theclaims.

That which is claimed is:

l. A tufting machine for forming narrow gauge pile fabrics including anelongate backing material and yarns penetrating the backing material andforming rows of tufts extending longitudinally of the backing material,said machine comprising a. a first row of spaced tufting needles mountedfor reciprocation in a direction transverse to the backing material andarranged to carry yarns through the backing material to form spacedapart first rows of tufts therein,

b. a second row of spaced tufting needles mounted for reciprocation in adirection transverse to the backing material and arranged to carry yarnsthrough the backing material, said second row of tufting needles beingwidely spaced from and offset relative to the needles of said first rowto form second rows of tufts in the spaces between the first rows oftufts.

c. pile forming means disposed beneath the backing material for formingpile from the yarns carried by said needles, and

d. positive positioning means for feeding the elongate backing materialbeneath said first and second rows of spaced tufting needles and forpreventing both lateral shifting and longitudinal sagging of theelongate backing material as it moves from said first to said second rowof tufting needles, said positive positioning means comprising 1. a pairof endless chains having upper reaches supported for movementtransversely of and adjacent opposite ends of said rows of tuftingneedies,

2. gripping means carried by said chains for engaging the side edgeportions of said backing material and for positively maintaining thelateral position of said backing material as it is moved from said firstrow to said second row of tufting needles by said chains,

3. a rotatable picker roll supported on a fixed axis extendingtransversely between said chains and parallel to said rows of tuftingneedles, and including outwardly extending pins adapted to engage thebacking material as the same is drawn over said picker roll, and

4. drive means for imparting movement to said chains, and for impartingrotation to said picker roll which is coordinated to the speed ofmovement of said chains.

2. A tufting machine according to claim 1 wherein said gripping meanscomprises a series of plates carried by and extending inwardly from eachof said chains, and pins carried by said plates and extending upwardlyalong the upper reaches of said chains.

3. A tufting machine according to claim 2 including guide trackssupported along the upper reaches of each of said endless chains andengaging said chains to maintain said chains moving in straight-linepaths of travel as they pass said first and second rows to tuftingneedies.

4. A tufting machine according to claim 3 including adjustment meansoperatively associated with at least one of said guide tracks foradjusting the distance between said tracks.

5. A tufting machine according to claim 3 including a first pair ofsprockets supported adjacent the leading ends of said chain guidetracks, and a second pair of sprockets supported adjacent the trailingends of said chain guide tracks, said sprockets supporting the upperreaches of said chains.

6. A tufting machine according to claim 5 including drive means forimparting reciprocation to said rows of tufting needles and wherein saiddrive means for said chains and picker roll is operatively connected tosaid needle drive means so that said chains and picker roll move thebacking material beneath said rows of tufting needles in timedrelationship to reciprocation of said tufting needles.

7. A tufting machine according to claim 6 wherein said picker roll issupported between said first pair of sprockets.

8. A tufting machine according to claim 7 including a pair of guiderolls engaging opposite side edge portions of the backing material priorto engagement with said picker roll, and pins extending outwardly fromsaid guide rolls for spreading the outer edge portions of the backingmaterial outwardly as it moves toward said picker roll and said pinscarried by said chains.

1. A tufting machine for forming narrow gauge pile fabrics including anelongate backing material and yarns penetrating the backing material andforming rows of tufts extending longitudinally of the backing material,said machine comprising a. a first row of spaced tufting needles mountedfor reciprocation in a direction transverse to the backing material andarranged to carry yarns through the backing material to form spacedapart first rows of tufts therein, b. a second row of spaced tuftingneedles mounted for reciprocation in a direction transverse to thebacking material and arranged to carry yarns through the backingmaterial, said second row of tufting needles being widely spaced fromand offset relative to the needles of said first row to form second rowsof tufts in the spaces between the first rows of tufts. c. pile formingmeans disposed beneath the backing material for forming pile from theyarns carried by said needles, and d. positive positioning means forfeeding the elongate backing material beneath said first and second rowsof spaced tufting needles and for preventing both lateral shifting andlongitudinal sagging of the elongate backing material as it moves fromsaid first to said second row of tufting needles, said positivepositioning means comprising
 1. a pair of endless chains having upperreaches supported for movement transversely of and adjacent oppositeends of said rows of tufting needles,
 2. gripping means carried by saidchains for engaging the side edge portions of said backing material andfor positively maintaining the lateral position of said backing materialas it is moved from said first row to said second row of tufting needlesby said chains,
 3. a rotatable picker roll supported on a fixed axisextending transversely between said chains and parallel to said rows oftufting needles, and including outwardly extending pins adapted toengage the backing material as the same is drawn over said picker roll,and
 4. drive means for imparting movement to said chains, and forimparting rotation to said picker roll which is coordinated to the speedof movement of said chains.
 2. gripping means carried by said chains forengaging the side edge portions of said backing material and forpositively maintaining the lateral position of said backing material asit is moved from said first row to said second row of tufting needles bysaid chains,
 2. A tufting machine according to claim 1 wherein saidgripping means comprises a series of plates carried by and extendinginwardly from each of said chains, and pins carried by said plates andextending upwardly along the upper reaches of said chains.
 3. A tuftingmachine according to claim 2 including guide tracks supported along theupper reaches of each of said endless chains and engaging said chains tomaintain said chains moving in straight-line paths of travel as theypass said first and second rows to tufting needles.
 3. a rotatablepicker roll supported on a fixed axis extending transversely betweensaid chains and parallel to said rows of tufting needles, and includingoutwardly extending pins adapted to engage the backing material as thesame is drawn over said picker roll, and
 4. drive means for impartingmovement to said chains, and for imparting rotation to said picker rollwhich is coordinated to the speed of movement of said chains.
 4. Atufting machine according to claim 3 including adjustment meansoperatively associated with at least one of said guide tracks foradjusting the distance between said tracks.
 5. A tufting machineaccording to claim 3 including a first pair of sprockets supportedadjacent the leading ends of said chain guide tracks, and a second pairof sprockets supported adjacent the trailing ends of said chain guidetracks, said sprockets supporting the upper reaches of said chains.
 6. Atufting machine according to claim 5 including drive means for impartingreciprocation to said rows of tufting needles and wherein said drivemeans for said chains and picker roll is operatively connected to saidneedle drive means so that said chains and picker roll move the backingmaterial beneath said rows of tufting needles in timed relationship toreciprocation of said tufting needles.
 7. A tufting machine according toclaim 6 wherein said picker roll is supported between said first pair ofsprockets.
 8. A tufting machine according to claiM 7 including a pair ofguide rolls engaging opposite side edge portions of the backing materialprior to engagement with said picker roll, and pins extending outwardlyfrom said guide rolls for spreading the outer edge portions of thebacking material outwardly as it moves toward said picker roll and saidpins carried by said chains.